Hot melt calendered or extruded wear layer for embossed substrates and method of manufacture

Abstract

The invention relates to a textured surface covering having a hot melt wear layer and methods of applying the hot melt wear layer to a textured or embossed surface without distortion of the visual image of the textured substrate. The wear layer substantially follows the contours of the substrate with minimum change in thickness of the wear layer over the textured surface and provides an aesthetically pleasing three dimensional appearance to the textured surface of the substrate. Melt applying the melt processable polymer resin to the textured substrate with a conformable pressure roll deter entrapment of bubbles between the wear layer and the textured substrate. Therefore, the wear layer exhibits significant clarity and visual depth, as well as improved maintenance (cleanability) properties. The resulting product has a visual image clarity reflecting any texture in the substrate including very light reflective (lenticular moray) embossings.

What is claimed is:  
     
       1. A method of manufacturing a floor or wall covering having a wear layer bonded thereto comprising the steps of: 
       a) heating a melt processable polymer resin composition to melt or soften the polymer resin composition;  
       b) applying the melted or softened melt processable polymer resin composition to a pre-textured surface of a substrate, the pre-textured surface having an area with a difference in height of at least about 1 mil vertical distance over no more than about 20 mils horizontal distance; and  
       c) cooling the melt processable polymer resin composition after it is applied to the pre-textured surface to form a textured surface covering for floor or walls comprising a wear layer bonded well on the pre-textured substrate, the wear layer having an average thickness of between about 2 mils to about 50 mils, the exposed surface of the wear layer closely follows the textured surface of the substrate,  
       wherein the wear layer is of substantially uniform thickness.  
     
     
       2. The method of  claim 1 , wherein the melt processable polymer resin composition is applied to the pre-textured substrate between a heated roll. or drum and a conformable. pressure. 
     
     
       3. The method of  claim 2 , wherein the melt processable polymer resin composition is formed into an ambient temperature film prior to being heated on the roll or drum. 
     
     
       4. The method of  claim 1 , wherein the melt processable polymer resin composition is formed into a layer in a calendar prior to being applied to the pre-textured surface of the substrate. 
     
     
       5. The method of  claim 1 , wherein the melt processable polymer resin composition is heated in an extruder. 
     
     
       6. The method of  claim 1 , wherein the average thickness of the wear layer is greater than 10 mils. 
     
     
       7. The method of  claim 1 , wherein the average thickness of said wear layer is between about 5 mils to about 50 mils. 
     
     
       8. The method of  claim 7 , wherein the average thickness of said wear layer is between about 10 mils to about 20 mils. 
     
     
       9. The method of  claim 8 , wherein the difference in height is at least about 2 mil vertical distance over no more than about 20 mils horizontal distance. 
     
     
       10. The method of  claim 9 , wherein the difference in height is at least about 5 mil vertical distance over no more than about 20 mils horizontal distance. 
     
     
       11. The method of  claim 1 , wherein the pre-textured surface is heated prior to the application of the wear layer composition. 
     
     
       12. The method of  claim 1 , wherein the melt processable polymer resin composition is heated on the roll of a calender. 
     
     
       13. The method of  claim 1 , wherein the pre-textured surface comprises fibrous matter. 
     
     
       14. The method of  claim 1 , wherein the pre-textured surface comprises deposited matter. 
     
     
       15. The method of  claim 14 , wherein the deposited matter is incompressible during application of the melted or softened polymer resin composition. 
     
     
       16. A method of manufacturing a textured surface covering having a wear layer bonded thereto comprising the steps of: 
       a) heating a melt processable polymer resin composition to melt or soften the polymer resin composition;  
       b) applying the melted or softened melt processable polymer resin composition to a pre-textured surface of a substrate, the pre-textured surface. having an area with a difference in height of at least about 1 mil vertical distance over no more than about 20 mils horizontal distance; and  
       c) cooling the melt processable polymer resin composition after it is applied to the pre-textured surface to form a textured surface covering for floor or walls comprising a wear layer bonded well on the pre-textured substrate, the wear layer having an average thickness of between about 2 mils to about 50 mils, wherein the melt processable polymer resin composition is applied to the pre-textured substrate between a heated roll or drum and a conformable pressure roll, and  
       wherein the melt processable polymer resin composition is heated on the roll or drum, prior to being applied to the textured substrate. and  
       wherein the exposed surface of the wear layer closely follows the textured surface of the substrate wherein the wear layer is of substantially uniform thickness.  
     
     
       17. The method of manufacturing a textured surface covering according to  claim 16 , wherein the melt processable polymer resin composition is formed into a layer in a calender prior to being applied to the pre-textured surface of the substrate. 
     
     
       18. The method of manufacturing a textured surface covering according to  claim 16 , wherein the melt processable polymer resin composition is heated in an extruder. 
     
     
       19. The method of manufacturing a textured surface covering according to  claim 16 , wherein the average thickness of the wear layer is greater 10 mils. 
     
     
       20. The method of manufacturing a textured surface covering according to  claim 16 , wherein the average thickness of said wear layer is between about 5 mils to about 50 mils. 
     
     
       21. The method of manufacturing a textured surface covering according to  claim 20 , wherein the average thickness of said wear layer is between about 10 mils to about 20 mils. 
     
     
       22. The method of manufacturing a textured surface coverage according to  claim 16 , wherein the pre-textured surface is heated prior to the application to the wear layer composition. 
     
     
       23. The method of manufacturing a textured surface covering according to  claim 16 , wherein the melt processable polymer resin composition is heated on the roll of a calender. 
     
     
       24. The method of manufacturing a textured surface covering according to  claim 16 , wherein the melt processable polymer resin composition is formed onto an ambient temperature film prior to being heated on the roll or drum. 
     
     
       25. The method of manufacturing a textured surface covering according to  claim 16 , wherein the pre-textured surface comprises fibrous matter. 
     
     
       26. The method of manufacturing a textured surface covering according to  claim 16 , wherein the pre-textured surface comprises deposited matter. 
     
     
       27. The method of manufacturing a textured surface covering according to  claim 26 , wherein the deposited matter is incompressible during application of the melted or softened polymer resin composition. 
     
     
       28. A method of manufacturing a textured surface covering having a wear layer bonded thereto comprising the steps of: 
       a) heating a melt processable polymer resin composition to melt or soften the polymer resin composition;  
       b) applying the melted or softened melt processable polymer resin composition to a pre-textured surface of a substrate, the pre-textured surface having an area with a difference in height of at least about 1 mil vertical distance over no more than about 20 mils horizontal distance; and  
       c) cooling the melt processable polymer resin composition after it is applied to the pre-textured surface to form a textured surface covering for floor or walls comprising a wear layer bonded well on the pre-textured substrate, the wear layer having an average thickness of between about 2 mils to about 50 mils,  
       wherein the melt processable polymer resin composition comprises a PVC resin and  
       wherein the exposed surface of the wear layer closely follows the textured surface of the substrate, wherein the wear layer is of substantially uniform thickness.